Apparatus for casting metals



Sept, 19, 1939, J.-A. SCHULTZ, JR. El AL APPARATUS FOR CASTING METALS 4 sheets-sheet 1 Original Filed March 19, 1934 VEN TORS 3% ML J A TTORNEYS.

Sept, 19, 1939, A. SCHULTZ. JR.. ET AL 2,173,377

APPARATUS FOR CASTING METALS Original FiledMarch 19, 1934 4 Sheets-Sheet 2 Sept. 19,- 1939.

J. AQSCHULTZ. JR.. El AL APPARATUS FOR CASTING METALS Original Fil'ed March 19, 1934 4 Sheets-Sheet 3 J I V EN TOR.

Sept. 19, 1939. J. A. SCHULTZ.IJR.. ET AL 2,173,377

APPARATUS FOR CASTING METALS Original Filed March 19, 1934 4 Sheets-Sheet 4 Patented Sept. 19, 1939 j UNITED srATss PATENT-"OFFICEH Hills, Ohio, and John A. Zapf, Toledo. Ohio, Zsfignors to Schultzlllachine Company, Toledo,

' Original application" March '19, 1934, sen-lain. 1 118,248. Divided and this application Januaryx .11, 937, Serial .No. 120,112 a Y Y "4 c aims, (01, 22-76) a This invention a division of copending appiica-. Figure 6 is a sectional view taken substantially tion, Serial No. 716,248, filed March 19, 1934, 're-. on the line 6-6 of Figure 4;

lates to the art of making castings from molten Figure '7 is a detailed sectional view showing the metal and particularly to an improved'apparatus d'ie operatingmechanism; used for making castings underpressure.

One of the objects of. the invention is to prostantially on the line 88 of Figure 7;

I vide a simple and efficientmeans operated by Figure 9 is a detailed sectional view taken su suitablepressure whereby thin section castings her having substantially the same temperature the efliciency of the machine for larger'scale proterioration of the metal is reduced to a minimum.

that changes in temperature or'pressuredue to cooperative relation;

arrangement, operation and function of the reand numerous other featuresas will be apparent stantially on the line 9-4 of Figure 7;

ure 10 is adetailed sectional view taken substantially on lines l0-l0 of Figure 7.- 10

We have illustrated our invention as incorporated in a die casting machine, but it is to be understood that we contemplate the use of our induction. usin le m ans to operate several in-. yention wherever the same may be found to be strumentalities in proper sequence. app1icable.- It is to be understood that we' do not 15 The invention so mb ac e p ov s on of wish to limit the same'torthe disclosure shown in safety meanswhereby the molten metal cannot be a th drawings, but that the same is used for ilforeed into the molds unless certain parts of the lustrating purposes only. machine a e in D OD p a ve re a i The method of our inventiton in one of its A ther ject of the invention is to provide aspects includes forcing into a mold or die the 2 a machine where the moltenmetal is charged metal to be castv at a temperature slightly into the molds or dies by displacement of a memhigher than its melting point or at a tempera- I ture where the metal could be termed as being at its plastic state, using, under such condition, for injecting the metal into the die a. pressure Another object of the invention is the pronot, 1es than one thousand pounds and not vision of an improved arrangement to retain at greater than two thousand pounds per square all times in fixed cooperative relation with the inch; the die casting mold being kept a substani metal forcing and delivering m ans 80 tially low temperature preferably at a temperacan be cheaply and rapidly made by persons un-' skilled in the art. Another object of the invention is the provision of an arrangement of parts which increases of the molten metal so that oxidation and dedisplacement of the metal does not affect suchtemperature of the injected metal.

As a practicalillustration of the method'of our Further objections and advantages are within invention we have found after considerable rethe scope of this invention such as relate to the searchzand' xperimentationthatwith zinc base lated elements of the structure, to various details. 735? Fahrenheitby *forcing the metal into the die of construction and to combinations of parts, r casting mold jt t perature ranging from elements per se, and to economies of manufacture 750 to 800 that is substantially at a temperature V ranging from 3 to 10'per'cent higher, than that of the melting point, employing an injecting pres- 40 sure of 1600 pounds per square inch; and retains ing the mold area in contact with the cast metal at a temperature ranging from 375 to 400, that is Fi re 2 i a detailed sectional w k n subs a temperature which is relatively lower than that stantially ontheline 2- 2 of Figure 1; of the injected metal, we have found that the Figure 3 is a w showing in deta l e t most satisfactory results are obtained when the parts of one of the safety features of the inventemperature is not higher than 60 percent of the tiOn? injected metal temperature. Careful tests show Figure 4 is' a top plane'view of the machine that the average tensile strength of castings prown n Fi ure 1; K ouced by our method is increasedby more than Figure 5 is a sectional view taken substantially 10 percent over castings producedby any other on line 5-5 ofFigu'rel showing thecooperative method, the'casting thus prod c be 9 re ation existing between the die holding plate porousand of remarlrable high density and we and the molten metal charging and delivering are capable of producing castings of greater unimeans;

from a consideration of the specification and drawings of a form of the invention. 1 Y

Figure 1 is a side elevational view of the machine of the invention;

Figure 8 is ahdet'ailed sectional view taken sub- 5 turethat does not exceed sixty percent of the 0 non-ferrousalloyshaving a melting point of 35 f formity all held within closer dimensional limits '55;

' The process of the invention. may be carried out by the utilization of machines of several types, and while we have disclosed the invention as being carried out in connection with a die casting machine using fluid pressure, it is to be understood that we contemplate the utilization of our process with all, kinds of machines whenever the same is found to be applicable, the machine disclosed herein being illustrated as one of the embodiments by which our method can be successfullyscarried in practice.

Figures 1, 4 and 6, the die casting machine illustrated as one of the embodiments by which the method of the invention can be carried out and other features of our invention comprises a frame Ill having a base portion ll forming the outer metallic casing of furnace l2 which is provided with a lining of fire brick I4 forming a fire or furnace chamber l5. The furnace chamber I 5 is closed at its upper end by a metallic plate I!) serving tosupport'a metal reservoir or melting pot 20 which extends downwardly from the plate withinthe furnace chamber l5, the melting pot 20 being heated by suitably regulated means conveyed through the furnace walls by means of a pipe 21 in order to maintain thelmetal in the reservoir in a molten condition at the desired temperature; Located within the melt;

-ing pot 20 is the suplemental pot or pressure delivery chamber 24 preferably of a goose-neck configuration which is s"bstantially immersed in the molten metal and is removably secured in fixed relation to the melting pct 20 by means of clamps 23 secured to plate l9. Member 24 is provided with a lateral connecting opening 26 whereby the molten material passes to a cylin- 7 drical bore or duct-25 connected by means of passage 21 to the delivering orifice or spout 28.

In order to force the molten metal into the dies, the cylindrical bore 25 of member 24 is adapted tosnugly receive a member or piston 30 which is adapted to be moved by means of rod 3| secured to a reciprocating piston 32 located withinthe cylinder 33. Cylinder 33 is fixedly supported upon plate I 9 by means of a plurality of upright supports 34.

Adjacent to the furnace l2 in proper spaced relation is a relatively stationary die holding plate 35 which is suitably supported and removably secured to supplemental pot or pressure chamber 24 by means of hinged members or eye bolts 36 having a threaded endportion adapted to receive nuts 31. Pressure chamber 24 is provided with projecting portions having suitable grooves 38 as shown in detail in Figure 5, which serve to receive bolts 36 and cooperating nuts 31 for the purpose of urging the molten delivering means of member 24 in proper positive engagement with the die holding plate '35. The die holding plate 35 is provided with extending leg portions 39, each carrying a wheel 4| engaging horizontal supports secured at one end to the walls of the furnace l2 by suitable brackets and at the other end by suitable supporting members or base support 42. This arrangement and type of support for the die holding plate 35'permits Referring to the drawings and particularly to the proper adjustability' of the same with respect to pressure chamber and also permits that the vided for supporting one of the die members relatively stationary and moving the other relative thereto. The latter means comprises a supporting and guiding frame 43 formed of a plurality of rods secured at one end to the relatively stationary die holding plate 35 and at its other end i by a subframe 55. 45 as particularly illustrated in Figures 1, 4, 5 and 6 is provided with bosses or integral projections 46 having openings through which passes the members 43 thus supporting the die holding plate 45 in proper alignment'and guiding it in A movable die holding plate its relative motion with respect to die holding plate 35. v

The die holding plate 45 is connected to an adjustable movable link 47 formed into two cooperating threaded portions, one of said portions terminating into a spherical end at which is received in a centrally located boss formed integral with die holding plate 45 forming a ball joint connection permitting the proper motion of member 41. The adjustable connecting link 4? is removably secured to plate '45 by means of a removable bracket, having atone end an openingrof similar contour to the spherical end of member 41 and having at its other end a frustroconical opening in order to permit oscillatory motion of member 41. Member 41 serves as a pressure equalizing device for the proper actuation and cooperative engagement of the relatively stationary die,member carried by die holding plate 35 and the cooperating die element carried by the movable die holding plate 45. Pressure equalizing member" is pivotally carried at its other end by a stub shaft 50- eccentrically carried by and between two oscillating members or gear segments 54 journalled by suitable shafts on subframe 55 which is also provided with suitable openings to receive guiding members 43. Frame 55 is adjustably supported in horizontal members 40 by means of a depending portion 56 upon which is journalled wheels 51 having a gear section 58 engaging the toothed rack 53 supported on members 40.

Movement of the die holding plate 45 towards and away from die holding plate 35 is accomplished through the movement of pressure equalizing member 41 caused by the oscillatory movement imparted to gear segments 54. Motion is imparted to gear segments 54 through the reciprocatory movement toothed rack 59 in engagement therewith, this reciprocatory movement being accomplished by the action of a piston 60 connected to the toothed rack 59 by means of a rod 6|, piston 68 being located within the pressure, cylinder 62. Movement of piston 60 within' the pressure cylinder 62 is obtained through the use of a suitable pressure, preferably fluid pressure, the. latter being controlled through suitable connecting valves located within the distributing chamber 63 which serves to connect either side ploy oil under pressure, the same being supplied 7 to the distributing chamber 63' through .aconduit 66 from a suitable oil pressure pump 61 driven by an'electric motor 68 both being supported upon a depending portion of sub-frame 55. Portion of the pump 61 and particularly the inlet conduits are located in the oil supply chamber forming part of the lowermost portion of sub-frame 55.

The oil under pressure produced by pump 6'| 'is controlled through the actuation of the suitable valves located within distributing chamber 63 containing suitable valves for establishing the connection of fluid to either side of the cylinder 62, through conduits 64 and 65, this control being accomplished through the use of a lever I8 which can'be manually or mechanically operated, movement of lever I8- is transmitted to the distributing chamber 63 by suitable links 12 and 13.

With the object of insuring the safety of the operator and preventing that molten metal be displaced from the pressure chamber 24 to the dies when the same are out of proper engagement, we provide interlocking means between the pressure actuating means for piston 32 which serves for forcing the molten metal into the dies, and. the operating means controlling the movable die holding plate 45, so that, the piston 32 can not be moved from its normal upper position unless the dies are in fixed cooperating relation. This interlocking means embraces the use of an upperiy projecting member 15 fixedly carried by toothed rack 59 which coacts with the control I8 of admission valve 84 which controls the injection of fluid under pressure to-cylinder 33 for the operation of piston 32, which as hereinbefore described imparts movement to plunger 38 for charging the molten metal intothe dies.

Member I5, as particularly shown in Figures 2 and 3, is provided with a narrow slot 88'terminating into a circularopening 8|. Slot 88 accommodates the side or parallel walls 82 of the rectangular section formed at one end of rod 83 adjacent to the portion to which is fixed the manual control or operating handle I8. The.

coaction of. slot 88 and the side walls 82 of rod 83, member "I8 cannot be moved unless the rectangular portion of rod 83 is located within the circular opening 8| present in member 15. Itshould be noted that the circular opening 8i will only be in registration with rod 83 when the piston 68 andrack '59 are at "their uppermost position, which takes place when the dies proper are in cooperative engaging relation. Under such condition, member I8 can be moved to either direction to control valve 84 for the injection of fluid under pressure to actuate piston 32. If, howeverfthe dies are not in proper cooperative relation, or rack 59 is not at its uppermost position, such actuation cannot take place. This safety feature is of material importance as the molten metal is never displaced from the melting pct 24 by member 38 unless the dies-are in proper engaging relation, thus preventing the metal from being splashed, causing injuries to the operator. The proper engagement of the toothed rack 58 with segmental gear 54 is accom 'plish'ed by the provision 'ofrollers 88 and 9| bearing against the rear face of the toothed rack member 59, these rollers being journalled on the side walls of sub-frame 55.

For the purpose of using diesof different types in order to produce castings of difierent, sizes and contours, the principal instrumentalities forming the machine of our invention are capableof relative motion, and the sub-frame 55 and the element carried thereby for this purpose is capable of adjustment with respect to the die holding plate 35, so that the movement imparted to toothed rack 59 by piston-68 to oscillate the pressure equalizing member" is not interfered with. Sub-frame 55 is held in position with re spect to die holding plate 35 through -the"use'of steps 95 in the form of clamps fixedly secured to rods 43, which coact with spacers in the form of U-shaped members 94 particularly shown in Figure 9, and nuts 96 coacting with the threaded portions 81 of members 43. By the use of spacers 84 which number and positioncan be changed with respect to the frontor'rear face of subframe 55 the position of such sub-frame and element carried-thereby can be movedas a unit thus permitting that dies of different depth can be carried by the die holding plate 35 and 45.

In orderto facilitate the movement of subframe 55 we have provided a lever 88 which co-" acts with wheels 51 journall'ed upon projecting portions 56o f sub-frame 55. .The wheels 51, as he'reinbefore pointed out, have segmental gear sections 58 which engage the toothed rack 53 carriedby the supporting members 48. Movement of the lever 99 will serve for changing the relative-position of sub-frame 55 withrespect to die holding plate 35. For the purpose of providing an accurate adjustment and proper engagement of the dieholding members carried by the die holding plates 35 and 45, respectively, the pressure equalizing member 41 consists of two sections, each provided with threaded cooperating portions I88 and IN, respectively. Adjacent to the threaded portion IN is a clamp I82, the latter serving to 'hold these portions in proper adjusted position preventing relative motion thus the desired length of member 41 is retained.

As particularly illustrated on Figure 10 an adjustable connection is present between racl; 59

and its actuating rod 6|, this connection consisting in forming on 58 a slot I85 adapted to snugly receive the threaded end I86 of rod 6|, the slot I85 serving to connect openings '8 and III which accommodate respectively nuts 4 and I I5 coacting with the threaded portion I86 of rod 6I in this manner'relative adjustment is obtained between rod' 6| and rack 59 for the purpose of accurately timing .the point of closure of the dies in the cycle of operation and this connection 59 has the required liberty. of movement to adjust itself automatically in. its guide eliminat- 'presentsthe further advantages that the. rack 6 of the drawings, a pyrometer I28 is immersed into the molten metal and through suitable wiring the same is; connected to atemperfature selector I24, the temperature selector being provided with a manual temperature setting device I26 for the purpose of controlling the current generated by pyrometer I20. The temperature selector I24 is connected to a suitable source of energy and in turn serves to energize a relay (not shown) for the purpose of opening or closing the circuit of an electric motor I26 directly connected to-the fuel supply valve I30. It can be seen that any change in temperature will, in the present instance, change the electron iotive force generated by pyrometer I and will in turn actuate motor I26 for the purpose oi regulating the flow of fuel to pipe 2I terminating in the furnace chamber I 5; We provide a by-pass I32 around valve I30 for the purpose of permitting manual regulation of the fuel delivered to chamber I5. The wall of furnace chamber I5 is provided with an opening I36 for the purpose of allowing the escape of burned gases, and aiding in proper combustion and circulation of theheat supplied.

In order to control the temperature of surface of contact of the die with the molten metal, the machine is provided with suitable cooling medium conveyed by means of suitable pipes I40, MI and I43 to manually controlled outlets adapted to be connected by flexible conduits to the die proper. The proper number oi effective conduits and the amount of cooling medium can be regulated manually by. valves I44, thus keeping the dies at all times at a predetermined substantially uniform low temperature. It can be seen that by the type of support of the pressure chamber 24 within the melting pot 20, thechange of the pressure chamber can be eifected any time without troublesome and time requiring work, and that the pressure and the amount of metal forced to the dies can be changed by the simple expedient of substituting the pressure chamber and the cooperating metal displacing member or plunger actuated by means of piston 32. This can be accomplished by the use of removable coupling I03 attached to the piston rod 3I, this type of arrangement permitting different types of metal displacing members to be used.

It should be noted that the delivering means of pressure chamber 24 are so positioned with respect totthe melting pot 20 that a portion of the passage 21, as well as spout or nozzle 23,- are located just above the edge of the melting pot and of the normal level of the molten metal con-. tained therein so that this portion partakes of the heat applied thereto so that a very small amount of metal is solidified in spout 26, the return stroke of plunger'30 acts to withdraw any molten metal from conduit 21 to the "level of the molten material on melting pot 20, thus leaving conduit 21 clear, and that it should also be noted that opening 26 of member 24 used for .ad-

mitting molten metal to duct for its injecting into the die proper is located below the normal level of the molten metal so that the metal injected into the die is at all times pure and tree from dross and other impurities. We have provided means to cushion the return stroke of the piston 32 actuated by fluid pressure for the pur pose ofgzontrolling the rapidity of movement and at thesame time the drawing back the metal in conduit 21 when the metal displacing member is raised by means of piston 32, this means being in the form of a valve I42 which permits the slow ejection of the air when the piston is re.- turned to, its uppermost position.

' In order to automatically eject castings when received in openings I and I 52' respectively on the movable die holdingplate 45. .These rods serve the purpose of engaging the die ejecting plate I54 carrying a plurality of knockout pins I56. As particularly illustrated in Figure 7, when the die holding plate !45 is movedaway from die holding plate 35, the rods I46 and I48 engage the die ejecting plate I54, causing relative motion between the die and the ejecting plate whereby the knockout pins I56, engage the casting thereby aiding in the removal of the castings from the die member. The rods I46 and I48 are capable of adjustment in sub-frame 55 by the use oi threaded portions I and I62 coacting withnuts I64 and I65.

The operation of the machine as hereinbefore described, could be summarized as follows. One complete cycle of the operation is now described. Assuming that the machine is in the position shown in Figures 1 and 6, wherein the sectional dies are in proper engagement the manual operating lever 16 which servesto actuate the'admission valve 64 moved from the full line position. to the dotted line position in the direction of the arrows as shown in Figure 3, this movement will permit the injection of fluid under pressure '--to the upper portionof cylinder 33 whereby piston 32 will'be moved downwardly, transmitting such motion through coupling I03 to member 30, the latter forcing the metal contained in ducts 24 and 21 through nozzle 26 into the sectional dies, the actuation of member I8 can be accomplished in this instance due t o the fact that the rectangular portion. of 63 is in registration with the circular opening 8I ofv member I5, due to the fact that the sectional dies are in properengagement and toothed rack 59 is in its uppermost position. v The pressure exerted by the fluid medium in cylinder 33 forces at a comparatively high pressure per unit'of area the molten metal hrough the displacement of member 30 in the die and holds the same until ithardens and the casting 4 is formed. During this'casting operation, the die holding plate 35 has been firmly locked and retained in fixed position with respect to the nozzle or spout 26 of pressure chamber 24 through bolts 36 as hereinbefore pointed out. 1 When the casting has hardened, the operating lever 16 is moved to its full line position whereby fluid pressure is admitted at the lower end of the cylinder 33-and atthe same time the pressure at the upper end of piston 32 is released. As soon as 5 the castinghas been hardened and with manual operating lever-I6 in its normal original position,

the movable die holding plate 45 is moved to the links 12 and 13 whereby the oil under pressure 6 is supplied through conduit 66 to the upper extremity oi pressure cylinder 62,-causing the downward movement of piston 60 carrying the toothed. rack 53 this movement of-the rack 53 ispermitted due to the fact that the rectangular portion of rod 0: is in proper registration with slot an of member I6. The downward movement of rack' 53 causes the rotation of segmental g'ear54, rotating the latter in a clockwise direction whereby pressure equalizing member 41 moves vdie hold- 1| ing plate 45 to the position indicated by dotted lines in Figure 1, separating the elements A and B of the sectional die, thus movement of plate 45 causes that the ends of'rods I45 and I48 engage casting ejecting plate I54 thereby forcing the knockout pins I56 to eject the casting from the dies.

In order to cause the engagement of the die elements A and B, for the purpose of stating the cycle of operation the die holding plate 45 is moved from the dotted line position to the full line position. This movement is accomplished through the manipulation of lever 10 in the opposite direction as the one indicated by the arrow, this movement causing the interconnection of conduit 64 with the oil under pressure and forcing piston 60 to its uppermost position whereby the segmental gear member 54 is moved in a counterclockwise direction as indicated by the arrows in Figure 7, causing the movement of die holding plate 45 towards the relatively stationary die holding plate 35, whereby the engagement of the I sectional die members A and B is established.

Movement of toothed rack 59 permits the proper registration of the circular opening 8| of member 15 with the coacting portion of manipulating rod 83 upon which is fixedly secured the manipulating lever I8. The machine is now ready for another operation. From the above description, it can be seen that the rate of the operation of the machine and the rapidity of the cycle is only dependent on the rate of cooling of the medium in the die proper and that the rapidity of the cooling can be effected by the use of a suitable cooling medium.

It is apparent that, within the scope of the invention modifications and different arrangements may be made other than is herein disclosed, and the present disclosure is illustrative merely, the invention comprehending all variations thereof.

What we claim is: I

l. A casting machine including a metal injecting mechanism; means to control said metal injecting mechanism including an oscillatable member having a portion of rectangular contour; a sectional die, a portion of said sectional die being held in fixed relation with respect-to said metal injecting mechanism; a mechanism for imparting motion to another portion of said sectional die toward and away from the relatively stationary die section; a member actuated by said mechanism having a slot terminating into a circular opening, said slot adapted to receive the rectangular section of said oscillatable member, the said second mentioned member being movable to a position whereby the circular opening is in registration with the rectangular portion of said oscillatable member when the sectional die elements are held in contact so as to effect the operation of said metal injecting mechanism by the actuation of said control means.

2. A casting machine including afluid operated mechanism for injecting the material to be cast to be received and project in the slot of said first mentioned member for locking the movable member relatively stationary; and die moving mechanism adapted to move the first mentioned member to a position whereby the enlarged opening is in registration with the projecting portion of said movable member when the die sections are held in contact so as to unlock the movable member to efiect the operation of the material injecting mechanism by the actuation of the control means.

3. A die casting machine including a relatively stationary member supporting a section of a sectional die; a second member supporting anothei' section of the said die adapted to be moved toward and away from said stationary die supporting member; a crank; a link; a ball and socket joint connecting said link to said movable die supporting member, said joint being centrally positioned with respect to the movable member, mechanism for actuating said crank and link to move said movable die supporting member, said link including adjustable means whereby when the die sections are moved into contacting position by said mechanism, said crank and connect ing link are in straight line relation.

4. A casting machine including a sectional die and a fluid operated mechanism for injecting the material to be cast into said sectional die; a relatively stationary member adjacent to said mechanism for supporting a section of the said die; a die moving mechanism for imparting motion to another section of said die toward and away from the relatively stationary die section and holding the die sections in contacting position; means associated with said fiuidoperated mechanism for guiding the material to be cast to saidsectional die; and a pair of tension members interposed between and directly connecting the guiding means with the relatively stationary'die supporting member, said tension members being hingedly secured at one end to the relatively stationary die holding member and having their other ends removably secured to said material guiding means, whereby the guiding means is held in intimate contact with the stationary supported section of said die.

' MARY T. SCHULTZ, Executn'a: of the Estate of Deceased.

JOHN A. ZAPF.

John A. Schultz, J12, 

